Just about to do my transfer box swap...

I'm about to put a 1.22 T/box in place of my 1.41 in the 90.

The box is out of a 200tdi Disco if that makes any difference.

Just wondered what consumables I need before I start?...i.e. gaskets, seals etc as I'm going to be vehicle-less once I start on it.

if going in a 300 tdi you wont need to alter hanbrake just swap assembly if going in to 200 or earlier then two 8 mm holes need drilling in rear of output housing for the hand brake bracket dont seal between both boxes but get new input seal for t/box icv100000 and fill reverse of seal with grease to hold garter spring in place while fitting seal ensure you set both diff lock and hi/low

Thanks James. It's a 200 tdi. Looks like I need a tap and die kit then (must remember not to drill too deep if I've read correctly - any idea how deep?) and the oil seal.

Also, how do you set both diff lock and hi/low? I've never done anything like this before...

25mm

Cheers

If your considering doing it by yourself, then be prepared for a long job.

It is a pain due to the whole angle of the xfer box, so 2 people to get it in is best mate, i'm happy to tackle any job on the landy on my own but if i did another xfer box i would have 2 people doing it.

As james said, the Disco handbrake set up will fit but the cable will snake towards the front of the landy, then back and then forward again to your handbrake lever.

Also check the Speedo fitting, mine came with an electronic one but the one from the 1.4 version fitted straight on

Lastly, consider removing the exhaust from the middle box back as it makes life a little easier.

:EDIT:

Dont forget to remove the difflock lever pin on the transfer box, remove the centre seat, drivers seat, panels underneath and the gearbox tunnel panel as well, will make it all abit easier for you

Thanks for that Badger...might put it off for a couple of weeks then, until I have some alternative transport while I carry this task out.

I tried to get a t/box with the cross drilled input shaft, but the guy said he thinks he only has 200's in stock, so it should be the old cable speedo take off. I will find out tomorrow anyway.

In fact, when I do it, I'll attempt to do a "how to" with photos for peoples future reference.

How to would be class mate, I have a disco one too but not sure about the tapping business!

Karlos28 said:

How to would be class mate, I have a disco one too but not sure about the tapping business!

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The tapping business is a piece of ****, ya just drill and tap the holes in the same place as on the defender tranny the hardest bit is lifting the fooker into place, when o did mine I had no one around to help except my 2 1/2 year old son, he wanted to help so while I balance it on the jack he pumped the jack up till it was in place (bless him it took him about 10 minutes to pump it up) but he's so proud he helped daddy fix the landy a bit of advice what I did was put 4lenths of threaded bar in the bolt holes on the gearbox and once tranny is in posision you can slide it onto gearbox nice and square without damaging the input seal

wangie46 said:

a bit of advice what I did was put 4lenths of threaded bar in the bolt holes on the gearbox and once tranny is in posision you can slide it onto gearbox nice and square without damaging the input seal

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get some machine screws, they don't have a thread on the entire length - makes the sliding process even easier

Thanks for the threaded rod tip. I was going to use some M10 100mm bolts with the heads cut off, but your way is cheaper....EDIT - Just seen Sean's post...

Next question...what do you guys think to these tap and die sets? Any good or?

Clarke CHT203 16-Pce Tap & Die Set - Machine Mart

Clarke CHT303 28-Pce Tap & Die Set - Machine Mart

Actually... I have just fitted one to my bosses landy and didn't swap the hand brake over.. Seems fine!?

thats probably because it was 300 or later with direct hand brake cable and no bracket

200tdi, and it still has the bracket, it's just sort of underneath rather than above like a defender..

Defender bracket is different, the disco sits higher hence why your cable snakes forward then back then forward, ie its too long.

So, can I get away with the Disco bracket as is, or do I need to drill and tap?

Well, I've done it and what an improvement!

Took me just over a day to do, which I didn't think was too bad saying that I was teaching myself as I went along.

I was going to do a how to, but it really is straight forward.

One thing to note though, I didn't drill and tap the transfer box for the handbrake bracket, I actually drilled holes in the bracket to line up with the existing holes...this works a treat.

If you want me to do an in depth "how to" then I shall

Very interested to see the pics and different stages of work. But most interested in your opinion on the gearing. Alot of talk has it that you lose a lot of low torqe.

depends on what you do, heavy towing ,slow work like off roading or normal driving